Director, Materials and Value Engineering @ Tower International
Production Control and Business Development Manager, Stamping Operations @ Chrysler
Senior Manufacturing Manager, Stamping Operations @ Chrysler
University of Michigan
Accomplished executive with successful leadership roles in operations, engineering, procurement, materials management, and business development. Vast expertise in manufacturing processes, materials optimization, procurement, and supply chain management. Recognized on an industry-wide basis for technical, business, and procurement expertise with the automotive metals and materials processing industries. Transformed business operations to long-term profitability with innovations that achieved unique
Accomplished executive with successful leadership roles in operations, engineering, procurement, materials management, and business development. Vast expertise in manufacturing processes, materials optimization, procurement, and supply chain management. Recognized on an industry-wide basis for technical, business, and procurement expertise with the automotive metals and materials processing industries. Transformed business operations to long-term profitability with innovations that achieved unique competitive advantages.Turned around failing operations that established profitability and saved more than 600 jobs.
Director, Materials and Value Engineering @ Responsible for leading materials management activities for global company with automotive, defense, industrial, alternative energy and aerospace operations.
Responsible for leading activities for all global business units: North America, South America, Europe, Korea, China, Defense and Aerospace.
Responsible for procurement and technical functions to optimize materials and supply chain management to achieve global business objectives and lowest overall cost.
Exceeded cost and profitability targets each year : Achieved over $70 million of savings to date. From 2009 to Present (6 years) Production Control and Business Development Manager, Stamping Operations @ Responsible for material procurement and supply chain management for new model programs and the development of associated systems and processes.
Transformed sheet steel material supply chain with improved processes, systems, and efficiencies.
Responsible for operational business and profit plans, product costing, quoting and sourcing of sheet metal products. Duties include establishing capital requirements and investment plans for new model projects and the procurement of new business.
Leadership role in automotive material strategies and joint business processes with material suppliers. From 2008 to 2009 (1 year) Senior Manufacturing Manager, Stamping Operations @ Responsible for operations leadership and profit and loss of metal fabrication & sheet metal assembly operations with annual sales of more than $500 million. Directed a staff and a total organization responsible for production operations, engineering, maintenance, and quality. Successfully implemented production and maintenance work teams and shop floor management.
Achieved profitability enhancement, throughput gains, and quality improvements:
• Reduced safety incident rate by more that 35%
• Reduced quality defect rates by 33% to 77%
• Improved Operational Equipment Efffectiveness (OEE) by more that 15%
• Achieved cost per unit improvements of more than 15% (monthly ranges of 15% to 31%) From 2007 to 2008 (1 year) Senior Manager, Quality, Business Systems & Launch @ Directed engineering, project and program management for new model stampings, quality, and the implementation of team-based manufacturing.
• Achieved cost, quality, and investment targets on new product launched.
• Achieved 42% reduction in defective product, 35% reduction in repairs, and 64% improvement in product quality utilizing Kaizen, six sigma, and disciplined process management.
• Achieved best corporate ISO9000 audits (without a finding)
• Successfully implemented team-based manufacturing. From 2006 to 2007 (1 year) Senior Manager, Materials & Manufacturing Engineering (Assembly, Stamping, & Components Operations) @ Division-level executive responsible for materials cost mangement (MCM) for manufacturing operations: served as co-Director for Material Cost Management (MCM) for body-in-white, stamping, and component operations.
• Oversaw $2 billion annual materials AVOB.
• Exceeded cost reduction targets for each of the five years involved in the process.
• Achieved annualized material cost reductions of $255 million
Division-level executive also responsible for engineering, quality, and program management for manufacturing division with seven sites producing modules and components for HVAC, engine cooling, emission systems, engine, powertrain, chassis, steering, and electronic products.
Scope of responsibilities included the following plant operations:
Toledo Machining, New Castle Machining, Dayton Thermal Products, McGraw Glass, Etobicoke Casting, Ajax Suspension Systems, and Huntsville Electronics.
Transformed business units to profitability with completely new products and technologies:
• Introduced new products and technologies to operations expanding business revenues and profitability (torque converters, suspension components and systems, steering columns, and evaporators)
• Improved labor efficiency 56% for component assembly lines with lean transformations linking assembly and machining work cells. ($28 million annual savings)
• Led company-wide implementation of TPM jointly with the corporate union leadership. Accelerated TPM implementation by 43%.
• Led assembly plant maintenance process improvements and standardization with plant management and union workforce teams.
• Led lean, six sigma, and black belt activities for the division.
• Exceeded quality targets and achieved $12 million of annual quality cost savings.
• Led turnaround of aluminum permanent mold and die casting operations. Prevented closure and outsource of plant operations (slashed scrap 50%, improved throughput 25%, and saved over 300 jobs) From 2001 to 2005 (4 years) Manager, Manufacturing Engineering @ Management executive responsible for engineering, maintenance, and business development for operation producing: heat exchangers, engine cooling modules, HVAC assemblies, emission control products and systems, and plastic and metal products (steel, copper, aluminum).
Achieved business transformation to long-term growth and profitability with the introduction of new products and process technologies:
• Implemented new aluminum brazing technologies reducing product costs by 24%, improving competitiveness and expanding business revenues.
• Exceeded cost and profitability targets each year.
• Led facility-wide transformation to lean manufacturing linking assembly lines to Injection molding machines:
• Reengineered layout adding manufacturing capacity to meet rapidly growing demands
• Improved productivity 41%, reduced scrap 27%, and cut inventory 60%
• Modernized stamping and plastic injection molding operations with improved process controls, quick tool change capability, standardized equipment, conveyors, and automation. Reduced molding cycle times by 35% and improved stamping throughput by 25%.
• Established shop floor based visual Kan Ban process
• Introduced high-speed assembly automation technologies eliminating manual assembly improving productivity by 35% and eliminating ergonomic safety issues.
• Insourced stamping die maintenance and introduced new die materials:
• Cut die maintenance costs 80% and unscheduled overtime 60%
• Implemented total maintenance system and team-based maintenance:
• Reduced plant downtime by 28%.
• First corporate plant registered to ISO9000. Corporate benchmark for lowest parts per million (PPM) rate of defective product.
• Achieved 80% improvement in warranty by successfully processing new but less manufacturable advanced materials.
• Successfully converted from Title V air emission status by revising stamping and thermal treatment processes. Received industry award for environmental excellence and achieved ISO14000. From 1996 to 2001 (5 years) Manager, Product Engineering and Quality Control @ Management executive responsible for Product Engineering, Materials Engineering, Quality Engineering, Supplier Quality Control, and Quality Assurance.
• Achieved three consecutive annual improvements in product quality of more than 60%.
• Achieved scrap rate reduction of more than 40% with nondestructive testing of welds and preventative quality systems for materials and processes.
• Recognized with Engineering Vice President Award for the implementation of formable prephosphated and medium strength steels for use in automotive body stampings.
• Achieved annual cost savings of more than $2 million, a 50% reduction in body damage issues, and an 80% improvement in J. D. Powers’ (product quality) scores.
• Awarded special Advanced Technical Training award for the resolution of defective welds associated with electrical power distribution. From 1992 to 1996 (4 years) Manager, Materials & Production Planning & Control @ Led Material Planning, Production Control Systems, Logistics, and inventory management for stamping operations.
• Achieved annual reductions of greater than 20% for both days of productive
inventory and excess transportation.
• Implemented electronic data interchange (EDI) and a comprehensive, integrated, on-line MRP system for the stamping plants From 1990 to 1992 (2 years) Manager, Steel Services @ • Achieved just-in-time shipments for sheet steel and an associated
inventory savings of more than 60% per year.
• Formulated and implemented quantitative and objective steel supplier rating system.
• Achieved 40% annual improvements in supplier quality (percent defective).
• Served as Chairman of Chrysler Anti-Corrosion Committee.
• Achieved annual warranty and manufacturing savings of over $10 million per year From 1988 to 1989 (1 year) Metallurgical Development Engineer @ • Responsibilities included the development and implementation of sheet metal products and processes for the manufacturing of automobiles and trucks.
• First individual recipient of Chrysler’s Chairman’s Award for cost and quality improvements and the establishment of statistical process control systems in manufacturing operations From 1985 to 1987 (2 years) Metallurgical Supervisor & Metallurgical Product and Process Engineer @ Duties included quality assurance, customer interface, and the development of plant practices for aluminum mill products including those for: armor plate and military applications, automotive body sheet and bumper stock, cans and containers, wirebar, forging stock, aircraft wing skins, and airframe structural plate.Interfaced with customers regarding new products, qualifications, and technical support.
• Improved first-time capability from less than 15% to more than 85% by reducing porosity defects and inclusions in air craft wings and aluminum plate stock by improving metal treatment and degassing processes.
• Turned around failing wire, rod, and bar operation returning it to profitability in four months by revising casting metal treatment and degassing practices and revising heat treatment practices
• More than doubled throughput, saved over 300 jobs. From 1980 to 1985 (5 years)
Master of Business Administration (M.B.A.) @ University of Michigan - Stephen M. Ross School of Business From 1985 to 1988 Master’s Degree, Materials & Metallurgical Engineering @ University of Michigan From 1983 to 1985 Bachelor’s Degree, Metallurgical Engineering @ Michigan Technological University From 1976 to 1980 Mark Autio is skilled in: Six Sigma, Materials Management, Procurement, Quality Control, Leadership, Cost Savings, Metallurgical Engineering, Supply Chain Operations, Automotive Engineering, Lean Manufacturing, Process Improvement, Continuous Improvement, Metals, Engineering, Process Engineering
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